Method of generating hydrogen and using the generated hydrogen

ABSTRACT

The present invention is directed to a hydrogen generating system which produces hydrogen instantaneously from water ready for use upon demand. The system includes a reactor that has reaction zones wherein catalyst and elevated temperatures generate hydrogen from steam. The zones in the reactor can be in the form of tubes about a heat generating chamber, and the zones are adapted to be interconnected to each other, to atmosphere, and to the source of steam, all to maximize the generation of hydrogen by providing a reactor of optimum flexibility. 
     The present invention also is directed to systems which include the hydrogen generating system and which utilize the generated hydrogen as a fuel or a chemical.

This is a division of application Ser. No. 175,597 filed Aug. 5, 1980,now U.S. Pat. No. 4,371,500, which is a continuation of Ser. No. 921,000filed on June 30, 1978, now abandoned.

FIELD OF INVENTION

This invention relates to a method of and apparatus for instantaneouslygenerating hydrogen from water upon demand, where needed as needed. Thisinvention also relates to systems which include the described method andapparatus and which utilizes the generated hydrogen.

BACKGROUND OF THE INVENTION

There is a continuing critical need to more efficiently produce hydrogenin substantial quantities for forming chemical products and in chemicalprocesses.

Presently, large quantities of hydrogen are consumed in the manufactureof ammonia and methanol, and in producing other alcohols, nitrates andamines. Hydrogen also is used in the hydrogenation of organic compounds,such as oils and fats to make margarine and vegetable shortening.

In the steel making industry hydrogen is being used in increasingquantities in the direct reduction of iron ores to produce metallic ironwhich may be fed to steel making furnaces, open hearth furnaces,electric furnaces and as part of the feed for blast furnaces.

Further, hydrogen can be used for such diverse uses as the gasificationand liquification of coal, the reduction of oxides of tungsten andmolybdenum to the metals, the providing of high protein foods throughbiosynthesis of hydrogen and carbon dioxide, and in total watermanagement programs to pasturize pathogens.

Apart from the growing need as a chemical, hydrogen, for some time, hasbeen considered as a possible alternative to fossil fuels: oil, naturalgas and coal. Hydrogen is an excellent fuel available in abundance.Water provides an undepletable supply of hydrogen. When it burns,hydrogen produces extraordinary quantities of heat and essentiallypollution free water vapor useful once again as a source of morehydrogen.

Prior to the present invention, however, hydrogen has not been producedupon demand in an economic manner.

Available systems, generally, do not provide hydrogen for instantaneoususe. Presently, existing systems commonly require production andstorage, or substantial accumulation, before utilization. There is nodirect link between production and use. Storage, a necessary element insuch existing systems, prohibits instantaneous use of hydrogen uponproduction.

This is not meant to say that storage is necessarily detrimental.Generally, however, the consumer has not had the option of eitherdirectly using the hydrogen or storing the hydrogen and using it whenneeded. Presently storage is required.

In addition, available systems do not produce hydrogen economically. Theprice for hydrogen is not competitive with available sources of energy.Also, it often takes more energy to produce hydrogen than the energyavailable from the produced hydrogen.

In sum, there is a need to more efficiently produce large quantities ofhydrogen for chemical purposes, and there is a pressing need to makeavailable an economic, ecologically sound energy generating system whichproduces hydrogen from water adapted for instantaneous use at the optionof the consumer.

It is a primary object of the invention, therefore, to provide a new andimproved method of and apparatus for producing hydrogen for chemical andenergy purposes.

It is another primary object of the invention to provide a newgenerating system which economically produces hydrogen from wateradapted to be used upon demand where needed, as needed, and which is animprovement of the system of my earlier patent, U.S. Pat. No. 3,967,589.

It is another object of the invention to provide a new system whichproduces hydrogen from water without substantially depleting the supplyof water or polluting the environment.

It is still another object of the invention to provide a new systemwhich produces hydrogen ready for instantaneous use without the need foran intermediate storage facility.

Another object of the invention is to provide a new energy system whichproduces low-cost hydrogen.

Among the other objects of the invention is to provide hydrogengenerating and utilizing systems for direct applications which servehuman needs, such as commercial, industrial and home heating, propulsionfor land, marine and aerospace vehicles, and the generation ofelectricity by utilities, by commercial and industrial enterprises, aswell as by the homeowner.

It is still a further object of this invention to provide a new andimproved hydrogen generating system for wherever hydrogen is usedchemically in forming hydrogen containing products as well as forprocesses where hydrogen can be used advantageously.

Additional objects and advantages will be set forth in part hereinafterand in part will be obvious herefrom or may be learned with the practiceof the invention, the same being realized and obtained by means of thesystems and applications, recited in the appended claims.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a hydrogengenerating system including a plurality of reaction zones which containcatalyst and which are maintained at elevated temperatures. Steam (orwater) is adapted to be conveyed to each catalyst containing zone,wherein hydrogen is generated from the steam (or water), and wherein thegenerated hydrogen is conveyed from the zone ready for use upon demand,where needed, as needed. The invention includes forming adjacentreaction zones in a reactor containing a catalyst in each zone, andmaintaining the zone at elevated temperatures, to produce hydrogen fromsteam fed thereinto. The zones in the reactor can be in the form oflongitudinal bores or tubes which extend along the length of the reactorabout a heat generating chamber. At least one end of the reactorincludes transverse and radial passages, adapted to interconnect thelongitudinal zones with each other, with the surrounding atmosphere andwith the source for steam, all to maximize the generation of hydrogen byproviding a reactor of maximum flexibility.

It is believed that hydrogen is generated by the invention because ofthe interaction of the high temperatures and the catalyst upon the steam(or water). At the high temperatures, it is believed the steam (orwater) becomes super heated steam which tends to disassociate in thepresence of the catalyst, to produce hydrogen gas. In any event, bypractice of the invention, hydrogen is produced from water which isinstantaneously available for use either as an essentially pollutionfree fuel, which, when burned, again produces water, or as a chemicalwherever hydrogen is required in products or processes.

The catalyst of the system, generally, is metallic and containsinnumerable sites on its surface, which, with the elevated temperaturein each zone, effect the generation of hydrogen. Illustratively, thecatalyst is formed of a web-like cellular structure defined byinterconnected metal filaments comprising iron, copper, silver, nickel,palladium, platinum, or iron-nickel and molybdenum.

Where the catalyst becomes deactivated because of use in the presentinvention, it is regenerated, in situ. For example, the innumerablereaction sites on a catalyst surface of iron will become oxidized by thesteam to produce hydrogen gas until the sites are oxidized. In suchinstance, the catalyst sites become deactivated. To reactivate the sitesa reducing agent, such as hydrogen or hydrocarbons or mixtures thereof,can be used. Once reactivated, steam can be fed to such catalyst to onceagain generate hydrogen.

As used herein, the term "deactivation" describes the condition of thecatalyst when it is no longer substantially effective as a catalyst inthe production of hydrogen, and the term "activated" describes thecondition of the catalyst when it is effective in the production ofsubstantial quantities of hydrogen.

In this embodiment of the invention, the generating system includescontrol means, responsive to the deactivation of the catalyst, adaptedto halt the supply of steam to the zone containing such catalyst and toprovide a catalyst regeneration agent which, once again, activates thecatalyst. At such time the control means are adapted to reverse theprocess by halting the supply of the regenerating agent and by supplyingsteam to the reaction zone for the generation of hydrogen.

A conduit system at each end of the reactor and connected to the zonesor tubes conveys fluid to and from the reactor. At one end, e.g.,upstream of the reactor, a control conduit circuit selectively providesto the tubes or zones steam from a steam generator for the production ofhydrogen and a reducing agent, such as hydrogen or hydrocarbon, to thetubes for the reactivation of the catalyst. At the other end, e.g.,downstream, the conduit system conveys fluids from the reactor,including the hydrogen generated within the reactor.

Once the system is in full operation selected zones or tubes willcontain an active catalyst while adjacent zones or tubes will containdeactivated catalyst. Under such conditions the control conduit circuitconcurrently provides steam to each tube containing active catalyst anda reducing agent, such as hydrogen, to each tube containing deactivatedcatalyst. In each active zone to which steam is supplied, the elevatedtemperatures and catalyst decompose the steam to produce hydrogen gas.This reaction is endothermic in nature because the heat is absorbed bythe reaction. Simultaneously, in each deactivated zone to which hydrogenis supplied, the reducing agent reacts with the oxidized catalyst toremove the oxygen from the catalyst surface to thereby regenerate orreactivate the catalyst. This reaction produces water and is exothermicin nature because heat is generated by the reaction. By conducting thedescribed reactions in adjacent zones, the exothermic heat is used toincrease the production of hydrogen by further elevating thetemperatures in a juxtaposed hydrogen generating zone.

To provide these concurrent reactions in adjacent zones, initially, thesteam can be supplied to one zone while nothing is supplied to theadjacent zone. Once the catalyst is deactivated in the one zone,concurrent operation can be commenced. For example, when there are eightzones positioned circumferentially about the heat generating chamber,initially steam can be supplied to every other zone (a set of fourzones). Once the catalyst in such every other zone becomes deactivated,then concurrent operations are commenced so that the exothermicreactivating reaction occurs in such every other zone while theendothermic hydrogen reaction occurs in the alternate adjacent zones (asecond set of four zones) with the aid of the exothermic heat.

Preferably, means are provided at the other end (downstream) of thereaction zones which can determine when the tubes are no longerproducing hydrogen because of deactivation of the catalyst. At this timethe control conduit circuit can cease providing steam to thenon-productive tubes and begin providing the hydrogen or hydrocarbons tosuch tubes to reactivate them. Once the catalyst has been regeneratedthe means will determine that regenerating hydrogen is being conveyedthrough that tube so that the control conduit circuit can reverse thedescribed procedure and begin to supply steam to the reactivatedcatalyst.

In the embodiment of the invention where the catalyst is not deactivatedby the steam, e.g., a catalyst formed from a platinum type of metal, theconduit system can continuously supply steam to each reactor tube andcontinuously convey the generated hydrogen therefrom.

In each embodiment of the invention the generating system can includedownstream cooling means for reducing the temperature of hydrogen andother fluids conveyed from the reactor. In doing so meaningfulreformation of the hydrogen and oxygen to form water is prohibited andthe temperature of the fluids is reduced to make them easier to handleby components of the system which separate and collect fluids, ashereafter described in more detail.

In addition, as hereafter explained in more detail, the method andapparatus of the present invention can be included in systems whichutilize hydrogen to form chemical products and in chemical processes, aswell as in systems which use hydrogen as a fuel for such diverseapplications as heating, propulsion and electricity.

BRIEF DESCRIPTION OF THE DRAWINGS AND ILLUSTRATIVE EMBODIMENT OF THEINVENTION

The following is a detailed description together with accompanyingdrawings of preferred and illustrative embodiments of the invention. Itis to be understood that the invention is capable of modification andvariation apparent to those skilled in the art within the spirit andscope of the invention.

In the drawings:

FIG. 1 is a perspective view of one embodiment of the invention.

FIG. 2 is an exploded, perspective view of the embodiment of theinventron shown in FIG. 1, wherein structure of several components ofthe system have been partially broken away to show details thereof.

FIG. 3 is a cross-sectional view of the upstream end of the reactor.

FIG. 4 is a cross-sectional view of the downstream end of the reactor,taken along the lines 4--4 of FIG. 1.

FIG. 5 is a longitudinal sectional view of a tube of the reactorcontaining one embodiment of the catalyst system of the invention.

FIG. 6 is a longitudinal sectional view of a tube of the reactorcontaining another embodiment of the catalyst system of the invention.

FIG. 7 is a magnified view of a portion of the catalyst of either FIGS.5 or 6.

FIG. 8 is a longitudinal sectional view of a tube of the reactorcontaining still another embodiment of the catalyst system of theinvention.

FIG. 9 is a longitudinal sectional view of a tube of the reactorcontaining still another embodiment of the catalyst system of theinvention.

FIG. 10 is a longitudinal sectional view of a tube of the reactorcontaining still another embodiment of the catalyst system of theinvention.

FIG. 11 is an end view of the upstream end of the reactor of thehydrogen generating system.

FIG. 12 is an end view of the downstream end of the cooling means of thehydrogen generating system.

FIG. 13 is a cross-sectional view of the cooling means of the hydrogengenerating system taken along the lines 13--13 of FIG. 12.

FIG. 14 is a planar view, diagrammatically illustrating theinterrelationship between the components and operation of the systemshown in FIGS. 1-2, and includes metering devices at the upstream end ateach of the reaction tubes.

FIG. 15 is a perspective view of another embodiment of a hydrogengenerating system of the present invention.

FIG. 16 is a cross-sectional view of the reactor of FIG. 15, taken alongthe lines 16--16, wherein a second set of transverse passages are shownfor interconnection of the illustrated reactor tubes.

FIG. 17 is a planar view, diagrammatically illustrating theinterrelationship between the components and operation of the systemshown in FIG. 15.

FIG. 18 is a perspective view of a further embodiment of the hydrogengenerating system of the present invention.

FIG. 19 is a planar view, diagrammatically illustrating theinterrelationship between the components and operation of the systemshown in FIG. 18 wherein the steam is fed into the catalyst in each ofthe reactor tubes.

FIG. 20 is a planar view also diagrammatically illustrating theinterrelationship between the components and operation of the system asshown in FIG. 18 wherein the steam is fed about the catalyst in each ofthe reactor tubes.

FIG. 21 is a perspective view, partially broken away, showing the energysystem producing hydrogen fuel for a boiler.

FIG. 22 is a perspective view, partially broken away, showing the energysystem of the invention for producing hydrogen fuel for a turbine.

FIG. 23 is a side view showing the system of the invention producinghydrogen fuel for a four cycle internal combustion engine.

FIG. 24 is a side view showing the system of the invention producinghydrogen fuel for the Wankel engine.

FIG. 25 is a front view, partially broken away, of a Stirling cycleengine which includes the hydrogen generating system.

FIG. 26 is a planar view, diagrammatically illustrating the reactor ofthe present invention for the Stirling cycle engine shown in FIG. 25.

FIG. 27 is a side view, diagrammatically illustrating the system of theinvention for producing hydrogen fuel for a fuel cell which generateselectricity.

FIGS. 1-14

Referring first to FIGS. 1-2, there is shown a preferred embodiment ofthe system 10 of the invention for producing hydrogen from water upondemand, where needed, as needed The system 10 includes a cylindricalreactor 12 about which is a cylindrical boiler or steam generator 14 inwhich steam is generated for the reactor 12. The reactor 12 has a heatgenerating chamber 16 disposed centrally of a plurality oflongitudinally extending, circumferentially spaced zones in the form ofeight bores or tubes 18a-h having a catalyst 20 in each tube. At eachend of the tubes 18a-h are transverse passages 22a-d -25a-d and radialpassages 26a-h and 28a-h for selectively connecting the tubes 18a-h witheach other, with the surrounding atmosphere, and with the steamgenerator 14. As shown, a network of conduits, generally identified thereactor 12 and boiler 14.

Steam Generator

The steam generator or boiler 14 includes an annular chamber 32 whichextends the length thereof for receiving water and generating steam forthe reactor 12. Extending through the boiler 14 is a central opening 34for slidably fitting the boiler 14 about the central portion of thereactor 12 where it is secured thereto by flanges 36.

A conduit 38 is connected into the lower portion of the chamber 32 forconveying water from a source (not shown) to the boiler 14 through acontrol valve 40. On the opposite side of the boiler 14, a conduit 42 isconnected into the upper portion of the chamber 32 for conveying steamto the reactor 12.

As shown the boiler 14 includes a pressure relief valve 41, a pressuregauge 43, and a sight glass assembly 45 with an upper valve 47 tomonitor the level of the water in the boiler and with a valve 49 fordrainage.

Reactor

In the embodiment of the invention shown in FIGS. 1 and 2, thecylindrical reactor 12 is integral being formed of a solid piece ofmetal with a large longitudinal central bore therethrough which formsthe heat generating chamber 16 and with eight smaller longitudinal borestherethrough circumferentially positioned about the chamber 16 whichform equidistant reaction zones or tubes 18a-h.

In the illustrative embodiment, a burner 44 is positioned within theupstream portion of the chamber 16 to provide heat from combustionderived from the fuel that issues from the burner 44. This heat issufficient to generate steam from water in the boiler 14 and tofacilitate and cause the reactions within the zones or tubes 18a-h forthe generation of hydrogen. The burner 44 is positioned within chamber16 so that the flame therefrom contacts the portion u of the tubes 18a-hwhich contain three catalyst 20. In other embodiments of the invention,described hereafter, the heat source required for the system of theinvention can be provided by rejected waste heat, or other suitablesources.

Extending from the chamber 16 is an exhaust conduit 45 for conveying theexhaust from the system.

As shown in FIGS. 3 and 4, the ends of the tubes 18a-h (upstream anddownstrea:m) are connected in pairs by transverse bores 22a, b, c and d,and 24a, b, c and d, respectively. Each transverse bore extends betweentwo longitudinal tubes, e.g., upstream transverse bore 22a interconnectsthe upstream ends of longitudinal bores 18a and b while downstreamtransverse bore 24a interconnects the downstream ends of the same tubes18a and b. For access, additional upstream and downstream transversebores 23a, b, c and d, and 25a, b, c and d extend from one of each ofthe interconnected pairs of the longitudinal bores, i.e., 18a, c, e, g,at the upstream and downstream ends thereof through the outer reactorwall. As shown, the transverse bores, e.g., upstream bores 22a, 23a,etc., downstream bores 24a, 25a, etc., are coaxial with the outer accessbores, e g., 23a and 25a being of greater breadth.

Also, the reactor 12 includes the radial bores 26a-h and 28a-h whichextend radially outward from each tube 18a-h at the end thereof,upstream and downstream respectively, through the outer wall of thereactor 12.

Thus, at each end of the reactor 12, the longitudinal tubes 18a-h areinterconnected in pairs by transverse bores 22a-d and 24a-d; areconnected to surrounding atmosphere by both the transverse access bores23a-d and 25a-d and the radial bores 26a-h and 28a-h; and are adapted tobe connected as will be described hereinafter, to the steam generator 14via the radial bores 26a-h and 28a-h.

Moreover, accessibility and interconnectability are selective. As shown,each of these bores and passages have threaded portions for the receiptof correspondingly threaded plugs 29 having slotted heads for suchpurposes. As desired, these plugs 29 may be removed for the passage ofsteam between adjacent tubes, e.g., tubes 18a, 18b, etc., for thepassage of steam through one or more radial bores, e.g., 26a or 28a,etc., for drainage of the tubes 18a-h through the same radial bores, orfor access to the interconnecting transverse bores, e.g., upstreamtransverse bore 22a via bore 23a, etc. In the illustrative embodiment,all the plugs 29 are in place so that pairs of tubes are notinterconnected, e.g., 18a is not connected to 18b via upstreamtransverse bore 22a, and the tubes are not open to atmosphere such as byradial bores 26a-h.

How removal of selected plugs 29 provides flexibility for the reactor 12is demonstrated hereinafter in connection with several embodiments ofthe invention.

Catalyst Systems

As illustrated in FIGS. 1 and 2, within the tubes 18a-h of the reactor12, are catalyst systems 20 of the invention for facilitating andcausing the separation of water vapor into hydrogen and oxygen.

In FIGS. 5-10 there are illustrated various embodiments of the catalystsystems 20.

In the embodiment of the catalyst system shown in FIG. 5, there isillustrated the catalyst 20 in the form of a spirally wound sheet 46positioned within the tubes 18a-h between two hollow end caps 48 heldtogether by wire 50 to form a cartridge slidably mounted within eachtube 18. Each cap 48 has a hollow sleeve 54 having holes 56 drilledtherethrough for the wire 50 and from which a hollow plug 58 extendsinwardly for abutment against the spirally wound catalyst 20.

In the embodiment of the catalyst system 20 shown in FIG. 6, thecatalyst 20 is cut from the sheet 46 into a number of discs 60juxtaposed between the porous end caps 48 and held together by the wire50 to form the slidably mounted cartridge.

As shown in the magnification of the catalyst 20 (FIG. 7) the catalystpreferably is formed from a powdered metal product defining a web-like,three dimensional, cellular structure in which the metal provides anetwork of interconnected metal filaments with interconnected,asymmetrical spaces or cells therebetween. By reasons of thenetwork-like, porous, cellular structure, the metal provides largesurface areas which are reactive sites. The metals which can be used forthe catalyst include iron, iron-nickel copper and molybdenum, palladium,and platinum. Several of these catalysts have been made available byFoammetal Inc. of Willoughby, Ohio, under the designation foametal, andare described in its 1974 brochure entitied "LOW DENSITY FOAMETAL, AStudy Of Surface Area, Texture, Cell Size And Filament Diameters".

In use, the porous catalyst systems 20 provide countless sites, which,with elevated temperatures, cause the steam to disassociate to formhydrogen gas.

Where the catalyst reacts with the steam, e.g., a catalyst formed ofiron, the countless sites are oxidized to produce an oxidized metalsurface and hydrogen gas. The decomposition of the steam passingtherethrough will continue until the metal essentially becomes coatedwith oxygen at which time the catalyst becomes deactivated. Toregenerate the countless sites, hydrogen can be fed through the tubes18a-h into contact with the catalyst 20 where the hydrogen reacts withthe oxygen on the metal surface to form water vapor and a free metalsurface.

As will be described hereafter in rore detail, decomposition of thewater to provide freed hydrogen occurs with the iron catalyst system 20in one tube 18, e.g., 18a, while oxygen is removed from the ironcatalyst system 20 in the adjacent tube 18, e.g., 18b. In doing so theheat of the exothermic reaction, which occurs in the tube 18 whereoxygen is removed from the catalyst 20, is used to increase theoxidation of the catalyst 20 in the adjacent tube 18 which produceshydrogen gas from steam.

Where the catalyst causes disassociation without reacting with thesteam, e.g., a platinum type catalyst, the water disassociates to formhydrogen and oxygen gases. In these embodiments the catalyst will notbecome deactivated under normal operating conditions so that hydrogengas can be produced in all the reactor tubes, e.g., 18a-h.

In the illustrative embodiments of the catalyst systems 20 of FIGS. 8, 9and 10, the catalysts are formed from the platinum type metals andalloys of Group VIIIB elements, and particularly platinum and palladiummetals and alloys. These platinum type catalysts are sufficiently porousso as to allow the permeation or diffusion of hydrogen therethroughwhile prohibiting the passage of water vapor and oxygen. These catalystsform a web-like cellular structure defined by interconnected platinumtype metal filaments which prohibit the passage of the larger watervapor molecules and oxygen, but which permit the smaller hydrogen atomsto pass therethrough.

Moreover, the platinum type metal catalysts of the invention areessentially self-sustaining under normal operating conditions. They donot become readily deactivated. They can remain active for extremelylong periods of time.

As shown in FIGS. 8-10 the catalyst systems 20 include a conduit 62wbich extends through the catalyst and which is slidably and removablysecured and positioned within a reactor tube 18. The conduit 62 has acentral portion 64 about which the catalyst 20 is mounted and throughwhich the diffused hydrogen can pass.

About one end of the conduit 62 (upstream), which extends from thecatalyst 20, there is a supporting and metering disk 66 (FIG. 8) havinga slip fit with respect to the conduit 62 an having a sliding fit withrespect to the reactor tube 18. About the outer portion of the disk 66are a plurality of U-shaped grooves 68 for directing and metering thepassage of steam downstream about the catalyst into the space betweenthe walls of the tube 18 and the outer periphery of the catalyst 20.

About the other end of the conduit 62 (downstream), which also extendsfrom the catalyst 20, there is a plug 70 welded to the conduit that isthreaded for reception by a correspondingly threaded end of the reactortube 18 for positioning and securing the catalyst system 20 in a gastight relationship in the reactor 12.

In the illustrative embodiment shown in FIG. 8 the hydrogen porousplatinum type metal catalyst 20 is in the form of a pluralitysuperimposed tubes 72 where the openings in each tube generally arenon-aligned or asymmetrical to facilitate the separation of thegenerated hydrogen from the other fluids in the reactor tubes 18. Asshown, there are two such superimposed hexagonally-shaped tubes 72 whichare fused together and which have ends 74 that are tapered inwardly tothe conduit 62 to contain the diffused hydrogen.

In the embodiment of FIG. 9, the already described catalyst 20 is in theform of a multi-layered spiral wound material bonded together to form acontinuous maze of increased surface area for diffusion of hydrogen.

In the embodiment shown in FIG. 10, the described catalyst ismulti-layered with a central core 76 from which extend a plurality ofradial webs or wings 78 along a length thereof to provide the increasedsurface area. The catalyst 20 is X-shaped with four radially extendingwebs 78.

With respect to the central portion 64 of the conduit 62, it can be madeof a hydrogen permeable metal, such as the platinum type metals (seeFIG. 9). In this embodiment the ends of the conduit 62 are formed froman inert non-diffusable metal, such as stainless steel, welded to thecentral porous portion 64

As shown in FIG. 8, the conduit 62 of the catalyst system 20 also canhave perforations 80 in the central portion 64 thereof for the receptionand passage of diffused hydrogen. In this instance the entire conduit 62can be made from stainless steel or other inert, non diffusable metals.

In the embodiments (FIGS. 8 and 10) the diffused or permeated hydrogenpasses through the conduit 62 while the remaining fluids (water, vaporand oxygen) flow through the space between the catalyst 20 and reactortube 18 through passages in the other end of the reactor 12.

Further, in these illustrative embodiments one end of each conduit 62 isclosed (upstream) so that the incoming steam cannot flow directly intothe conduit 62. Instead it flows about the catalyst 20 as has beendescribed.

In an embodiment of the catalyst system 20, such as shown in FIG. 9, thesteam can be fed into conduit 62 and the hydrogen can diffuse throughthe hydrogen permeable central portion 64 and catalyst 20 into thereactor tube 18, while the remaining fluids pass downstream through theconduit 62.

Conduit System

As an introduction to the conduit system 30, and in addition to theconduits already described, the system 30 conveys fluids to and from thereactor 12 by upstream manifolds 96 and 98 and downstream conduits100a-h, and controls the flow of fluids through the reactor 12 by acontrol circuit connected to the upstream manifolds 96 and 98. Ingeneral, there are a pair of manifolds (96 and 98) upstream of thereactor 12, for conveying fluids thereto, wherein each manifold has acircular conduit and four spoke or branch like conduits which extendtherefrom and which are connected to four tubes 18. Specifically:

the upstream manifold 96 has a circular conduit 104 and four inwardlyextending L-shaped curved conduits 106, 108, 110 and 112 threadably andremovably connected to longitudinal bores 18a, c, e and g in a fluidtight relationship (See FIGS. 1, 2 and 11); and

the upstream manifold 98 has a circular conduit 114 and four inwardlyextending L-shaped curved conduits 116, 118, 120 and 122 threadably andremovably connected to longitudinal bores 18b, d, f and h in a fluidtight relationship (See FIGS. 1, 2 and 11).

The control circuit 102 controls the flow of fluids to and through thereactor 12 by selectively providing steam to produce hydrogen, and, asnecessary, hydrogen to reactivate the catalyst in the tubes 18a-h.

In the illustrative embodiment, the tubes 18 operate in two sets of fourtubes each. When on stream, hydrogen will be generated in four tubes,e.g., 18a, c, e and g, while the catalyst 20 will be regenerated in thetubes 18b, d, f and h, between or adjacent to the first set of tubes18a, c, e and g. This process will be reversed when the catalyst 20 intubes 18a, c, e and g becomes deactivated while the catalyst 20 in tubes18b, d, f and h has become regenerated. During each cycle, moreover, thereaction in the tubes where catalyst regeneration is occurring willprovide heat which increases the amount of hydrogen being generated fromsteam in adjacent tubes.

In the illustrative embodiment of the invention shown in FIGS. 1 and 2,the circuit 102 includes a rectangularly shaped loop above the boiler 14which has four legs: two transverse legs 126 and 128, and twolongitudinal legs 130 and 132.

Centrally connected into the transverse leg 126 is the steam conduit 42with valves 134 and 136 on either side thereof. Correspondingly,centrally connected into the transverse leg 128 is a conduit 138 whichconveys a regeneration agent, such as hydrogen, from a source (notshown) for the regeneration of catalyst 20. Here too valves 140 and 142are connected into the transverse leg 128 on either side of conduit 138.

Centrally connected into the longitudinal leg 130 is a pressure gauge144 for measuring and controlling steam pressure, and a conduit 146 forselectively conveying steam or regenerating agent to manifold 96.Similarly centrally connected into the longitudinal leg 132 is apressure gauge 148 also for measuring and controlling steam pressure,and a conduit 150 for selectively conveying steam or regenerating agentto manifold 98. Typically, the steam supplied to the reaction tubes18a-h can be at a controlled pressure of about 3 p.s.i.g.

Downstream of the reactor are the conduits 100a-h connected in fluidtight relationship to the downstream end of the tubes 18a-h forconveying fluids, generated hydrogen, oxygen and water vapor therefrom.From these conduits 100a-h the fluids are conveyed into a temperaturereducing means 152 where the fluids are collected and cooled. From thetemperature reducing means 152, a pair of conduits 154 and 156 conveythe fluids through gas detectors 158 and 160, which measure the yield ofhydrogen, and into separators 162 and 164, where the fluids areseparated with the hydrogen being conveyed to the collectors 166 and 168and the other fluids being conveyed to collectors or separators 170 and172.

The temperature reducing means 152 lowers the temperatures of the fluidsto increase the yield of hydrogen. Cooling prevents the gases formedfrom the steam, hydrogen and oxygen, from reforming into water vapor orwater. The reduction in temperature also makes the fluids easier tohandle downstream.

In the illustrative embodiment shown in FIGS. 1, 2, 12 and 13, thetemperature reducing means 152 is a water cooled heat exchanger orquencher having a shell which includes a chamber 176 formed by acylindrical housing 178 and upstream and downstream end plates 180 and182 welded to the inner periphery at the upstream and downstream ends ofthe housing 178. The cylindrical housing includes a series of fins 184to increase the surface area for cooling purposes, and the upstream anddownstream end plates 180 and 182 include central openings 186 and 188therethrough.

Positioned within the chamber 176 spaced from the housing 178 and endplates 180 and 182 for the circulation of a cooling medium, such aswater, the quencher 152 includes manifold 190 having a central opening192 therethrough and two outer annular chambers 194 and 196 formed byspaced annular partitions 198 and an outer two segmented cover 200welded thereto. Extending through the central openings 186, 188 and 192of the end plates 180 and 182 and the manifold 190 is an inner tube 202which is welded to the inner periphery of the end plates 180 and 182.The manifold 190 also includes a plurality of the longitudinal grooves204 therethrough which, with the space 205 between the inner tube 202and the manifold 192 define passages to facilitate the flow andeffectiveness of the cooling medium.

Extending from the upstream end of the manifold 190 there are eightpassageways 206a-h therewithin: four passageways 206a, c, e and g extendinto one annular chamber 194 and four passageways 206b, d, f and hextend into the other annular chamber 196. In the illustrativeembodiment the downstream conduits 100a, c, e and g extend through bores208a, c, e, and h in the upsteam end plate 180 and are connected in afluid type relationship into one set of passageways 206a, c, e and gwhile the other downstream conduits 100b, d, f and h extend throughbores 208b, d, f and h in plate 180 and are connected in a fluid typerelationship into the other set of passageways 206b, d, f and h.

In use, fluids from the reactor 12 are conveyed through the conduits100a-h and into the chambers 194 and 196 via the appropriate set ofpassageways 206a, c, e and g or 206b, d, f and h. For cooling thesefluids, a conduit 210 is connected into the downstream end plate 182which conveys a cooling medium such as water, from a source (not shown)into the quencher chamber 176. For conveying the cooling medium from thechamber 176, a conduit 212 is connected to the upstream end plate 180and a reservoir (not shown). Within the chamber 176, the cooling mediumflows about the manifold 190 and through the grooves 204 and space 205about the inner tube 202 to reduce the temperature of the reactor fluidscollected in the annular chambers 194 and 196.

For conveying the cooled reactor fluids downstream of the quencher 152the conduits 154 and 156 extend from the annular chambers 194 and 196,respectively, and through bores 154a and 156a in the end plates 180 and182.

The downstream gas detectors 158 and 160 provide a control over theproductivity of the reactor 12 and the reactivation of catalyst 20 inthe tubes 18a-h. The gas detectors 158 and 160 indicate whether hydrogenis being generated within each set of four tubes 18a, c, e and g, and18b, d, f and h. When a gas detector 158 or 160 shows little, or nohydrogen is being conveyed through the appropriate conduit 154 or 156,this normally indicates that the catalyst 20 in the operativelyconnected tubes 18 has been deactivated. The sequencing of valves 134,136, 140 and 142 in the upstream control circuit 102 then is set toprovide hydrogen and not steam to the appropriate set of tubes toreactivate or regenerate the catalyst 20 therein. When the gas detector158 or 160 again provides high hydrogen readings this indicates thatregeneration of catalyst has occurred and the steam cycle can commenceagain. At such time the sequencing of the valves 134, 136, 140 and 142is reset to shut off the supply of hydrogen to such catalyst and toconvey a fresh supply of steam thereto.

In the illustrative embodiment, the gas indicators 158 and 160 are readby an operator and the valves 134, 136, 140 and 142 are set and resetmanually. It is within the scope of this invention to provide forautomatic means to open and close the valves 134, 136, 140 and 142responsive to the detection of hydrogen or other fluids in the conduits154 and 156. Such automatic means can be electrical, hydraulic,pneumatic or mechanical, or a combination of such means.

Downstream of the quencher 152 and gas detectors 158 and 160, the cooledfluids are separated with the hydrogen and oxygen ready for use orcollection. In the illustrative embodiment the separators 162 and 164are those disclosed in my earlier U.S. Pat. No. 3,967,589. Eachseparator 162 or 164 includes a tubular housing 214 in which there isdisposed an active microporous asymmetric membrane 216. The membrane 216is a thin, selectively permeable film having a porous supportingsubstrate which has been rolled to form a tubular asymmetric microporousmembrane. These membranes are sold by the Roga Division of Universal OilProducts, Company, 2980 Harbor Dr., San Diego, Calif. 92101 and aredescribed in its brochure, Membrane Production of Nitrogen Enriched AirFor Fuel Tank Blanketing Applications, dated September 1974.

Extending through each membrane 216 and from the downstream end of thehousing 214 is a conduit 218 having perforations 219 (FIG. 14) along thelength which lies within the membrane 216 Also, extending from thedownstream side of each housing 214 is a conduit 220 which opens intospace between the membrane 216 and housing 214.

As the fluids are conveyed from the conduits 154 and 156 into eachhousing 214, the pressure of the fluids and the porosity of eachmembrane 216 is such so as to allow only hydrogen to be diffusedtherethrough. The separated hydrogen then passes through theperforations 219 in each conduit 218 and is conveyed downstream readyfor use.

At the same time the oxygen and water collected in each housing 214about each membrane 216 is conveyed downstream by the conduit 220 wherethe oxygen can be separated from the water and used as desired.

As shown in the illustrative embodiment, the separated hydrogen in eachconduit 218 and the oxygen and water vapor in each conduit 220 can befed into the appropriate collectors and separators 166, 168, 170 and172.

Operation

Referring first to FIG. 1, at start up, the valves 134, 136, 140 and 142are closed. Water, as needed, is supplied to the boiler 14 throughconduit 38 and fuel is supplied to the burner 44 and ignited, to therebyprovide heat for the generation of steam and heat for the tubes 18a-hand catalysts 20 therein. When steam has been generated, valve 136 isopened and the steam at a controlled pressure and flow rate is suppliedto a set of four tubes, e.g., tubes 18a, c, e and g, via the upstreamconduit 146 and manifold 96, wherein the steam is elevated totemperatures at which it reacts with the catalyst 20 in these tubes 18to form hydrogen and minor amounts of water vapor and oxygen. Thesefluids are conveyed from tubes 18a, c, e and g through the downstreamconduits 100a, c, e, and g and into quencher chamber 194 where thetemperature of the fluid is reduced by water circulating through thechamber 176 and grooves 204 to inhibit reformation of the hydrogen andoxygen gases. From the quencher 152 the cooled fluids are conveyed intoand through the separator 162 where only the hydrogen diffuses throughthe membrane 216 into the conduit 218 and is conveyed to the collector166 ready for use. At the same time the non-diffused fluids (oxygen andwater vapor) pass through the housing 214 and into the conduit 220 andcollector 170 for further processing, as desired.

This start up operation will continue until the downstream gas detector158 indicates that meaningful quantities of hydrogen are not beinggenerated in the tubes 18a, c, e and g. This reading shows that thecatalyst 20 therein has been oxidized and become deactivated.

At such time, and now referring to FIG. 14, valve 136 is closed andvalve 140 is opened to provide hydrogen to the tubes 18a, c, e and g viaupstream conduit 146 and manifold 96 to regenerate the catalyst 20therein. Concurrently valve 134 is opened to provide steam to the otherset of tubes 18b, d, f and h, via the upstream conduit 150 and manifold98, wherein the steam reacts with catalyst 20 therein to producehydrogen gas and minor amounts of water vapor and oxygen.

With these ongoing concurrent operations, the heat from the exothermicreaction occurring in tubes 18b, d, f and g is used to generate hydrogenoccurring in the adjacent tubes 18a, c, e and g. Also, the amount offuel being supplied to the burner 44 can be reduced because of the heatfrom the exothermic reaction is being used to generate hydrogen.

From the reactor 12 the generated hydrogen and minor amounts of oxygenand water vapor are conveyed from tubes 18b, d, f and h through theconduits 100b, d, f and h into the quencher chamber 196. Simultaneously,fluids, water vapor and gases, are conveyed from the reactor tubes 18a,c, e and g, wherein the catalyst is being reactivated, through thedownstream conduits 100a, c, e and g into the quencher chamber 194. Thefluids in the quencher 152 are cooled by the water flowing therethroughto reduce the temperature thereof to inhibit reformation of the gases.As shown in FIG. 14, from the quencher 152 the fluids in chambers 94 and196 are fed into the separators 162 and 164 via conduits 154 and 156 forrecovering the hydrogen generated in tubes 18b, d, f and h, as well asany residual amounts of hydrogen not consumed in the reaction inregenerating the catalyst 20 in tubes 18a, c, e, and g. In eachseparator 162 or 164 hydrogen diffuses through each membrane 216 andperforations 219 in the centrally positioned conduit 218 and is conveyedinto collectors 166 and 168 ready for use. Simultaneously the fluidswhich cannot permeate the membrane 216, e.g., water vapor and oxygen,pass about the membranes 216 and through the conduits 220 into theseparators 170 and 172.

These concurrent operations, which represent the full cylce ofoperation, will continue until the gas detector 160 for the tubes 18b,d, f and h indicates that hydrogen is no longer being produced in suchtubes in meaningful quantities because of deactivation of the catalyst20 therein. At this juncture the other gas detector 158 operativelyconnected to the other tubes 18a, c, e and g will show meaningfulquantities of hydrogen being passed through the conduit 154 whichindicates that the catalyst 20 in such tubes has been reactivated, readyonce again to produce hydrogen. The opening and closing of the valves isreversed so that steam is supplied through valve 136 to the tubes 18a,c, e and g as hydrogen is suppIied through valve 142 to the tubes 18b,d, f and h, thereby reversing the reactions in each set of four tubes.

Thus, by the practice of the present invention, hydrogen is continuouslyproduced ready for use upon demand, where needed, as needed.

As an illustrative example of the hydrogen generating system 10 shown inFIGS. 1-2 and 9-14, the reactor 12 is about 15 inches in length and 6.15inches in diameter, while the centrally positioned boiler 14 is about 10inches in diameter. Typically, the reactor tubes 18a-h, which also areabout 15 inches in length, are about 0.875 in diameter.

As shown, the water quencher 152 is about 5.0 inches in length and about10 inches in diameter, and the inner tube 202 has a diameter of about3.125 inches. Within the quencher 152 the manifold 190 has a length ofabout 4.0 inches, and an outer diameter of about 6.5 inches.

Further in the illustrative embodiment of FIG. 14, a metering device 221at the upstream ends of each of the tubes 18a-h is provided whichcontrols the flow of steam and hydrogen thereinto.

In the embodiment where the catalyst becomes deactivated and isregenerated as just described, moreover, a foametal catalyst of iron isused. Where the foametal catalyst of iron is wound in a spiral sheet 46as shown in FIG. 5, its length can be about 2.0 inches and its diametercan be from about 0.5 to 0.625 inches. Where the foametal catalyst ofiron is the form of a series of juxtaposed discs as shown in FIG. 6,each disc can be about 0.125 in thickness and the combined length of thejuxtaposed discs also can be about 2.0 inches in length.

Whether the catalyst 20 is in the form of a sheet or discs, thetemperature of the steam in the reactor is raised to about 1000°F.-1800° F., at which temperature, and with such catalysts, the steamdisassociates and hydrogen is generated.

In the practice of the invention the required quantities of fuel for theburner 44 and the regenerating agent for the deactivated catalysts aresubstantially less than the hydrogen generated, resulting in anefficient system.

As will be described in the next several embodiments, platinum typecatalysts, which normally do not need regeneration, can be used toachieve even greater efficiencies.

FIGS. 15-18

Referring generally to this and other embodiments of the inventionhereinafter described, like reference numbers refer to like parts of thesystem which have been already described.

In the embodiment shown in FIGS. 15-18, steam is fed from the steamgenerator 14 into the downstream end of the reactor 12 wherein the steamflows in a serpentine path through interconnected tubes 18a-h containingplatinum type catalyst systems 20.

As shown in FIG. 15, steam is conveyed to the downstream radial bore 28hof the reactor 12 by the steam conduit which includes a valve 222 andpressure gauge 224 that monitors and controls the pressure and flow ofsteam therethrough.

To provide the serpentine path for the flow of steam within the reactor12, a second set of transverse bores 24e-h in the downstream portion ofthe reactor 12 connect alternate pairs of longitudinal reactor tubes,i.e., 18b-c, 18d-e, 18f-g and 18h-a (See FIG. 16).

Taken together the most downstream transverse bore 24a-d, shown indetail in FIG. 4, connect the longitudinal tubes 18a-h in pairs: 18a-b,18c-d, 18e-f and 18g-h while the next downstream transverse bores 24e-h,shown in detail in FIG. 16, connect the longitudinal bores 18a-h inpairs: 18b-c, 18d-e, 18f-g and 18h-a.

As with their counterparts, transverse bores 24e-h also are threaded andare connected to threaded, transverse access bores 25e-h. In each ofthese bores, moreover, removable plugs 29 are provided.

In this embodiment platinum type catalyst systems 20, such asillustrated in FIGS. 8-10, can be used.

As has been previously explained with a platinum type catalyst,deactivation normally does not occur and regeneration is, therefore, notrequired. Accordingly, feeding steam and a regenerating agent to aparticular tube 18 or set of tubes 18, on an alternating basis, is notneeded. Also, downstream of reactor 12, the quencher manifold 190 needonly have one cooling chamber 194 and there need be only one separator162 downstream thereof. In addition, a downstream gas detector, such asdetectors 158 and 160, shown in FIG. 1, becomes optional becausehydrogen will be generated on a continuous basis within the platinumtype, catalyst containing reactor tubes 18a-h.

As shown in FIG. 17 radial bore 26h has been opened by removing the plug29 therein and is connected to the steam conduit 42 in a fluid tightrelationship. At the same time the transverse bores 24e-g and bores22a-d are opened by removing plugs 29 while the remaining bores(transverse bores 24a-d 24h and radial bores 26a-h and 28a-g) areclosed.

In operation the burner 44, or other source of heat, effects thegeneration of steam within the boiler 14 and the steam is fed from theboiler 14 to the reactor tubes 18a-h through the conduit 42 under acontrol led rate of flow and pressure, e.g., 3 p.s.i.g. The flow rateand pressure is sufficient for passage of steam through theinterconnected tubes 18a-h and for disassociation of steam to hydrogen.

From the conduit 42 the steam initially flows through the radial bore26h and into the adjacent end of the reactor tube 18h. The steam withinthe tube 18h is raised to disassociation temperatures of about 1000° F.to 1800° F. by the burner 44 and with the platinum type catalyst system20 effects disassociation. As previously explained, only hydrogen isallowed to diffuse through the platinum type catalyst 20 and into thecatalyst conduit 62 for flow from the reactor 12 through conduit 100hinto the water quencher 152. At the same time the steam, which has notdisassociated and the oxygen from the disassociated steam, flows aboutthe catalyst 20 to the other end of the reactor 12 and through thetransverse bore 22d and into the reactor tube 18g where the process isagain repeated. As shown by the arrows indicating the flow of steam, anyremaining steam and disassociated oxygen moves in a serpentine paththrough the remaining tubes 18f-18a and transverse bores 22c-a and 24g-efor further disassociation. The diffused hydrogen in the conduits 62 andin the tubes 18a-h flows as indicated from the reactor 12 through theconduits 100a-h into the quencher chamber 194. At the same time residualsteam and disassociated oxygen in the last tube 18a are conveyed fromthe downstream end of the reactor 12 through reactor bore 226 into aconduit 228 connected thereinto in a fluid type relationship. A valve230 in the conduit 228 regulates the flow therethrough by throttling, tocontrol, by back pressure, the pressure of the fluids within the reactortubes 18a-h and optimize the generation of hydrogen therein.

As illustrated, each of the conduits 62 of the catalyst systems 20 alsocan be connected at their other ends, in a fluid type relationship, witha manifold 231 which includes control valve 232. In use, this controlvalve 232 can be opened and closed to provide a positive or negativepressure, as desired, for urging hydrogen gas in the catalyst conduits62 into the quencher 152 or for exhausting gases from the catalystconduits 62 through the manifold 231.

In addition, downstream of the quencher 152 the cooled hydrogen gas canbe fed into and through the previously described separator 162 tofurther ensure the separation of hydrogen from any residual fluids whichmay have diffused through the platinum type catalyst along with thehydrogen.

FIGS. 18-20

In FIG. 18 there is shown an embodiment of the invention with a singleupstream manifold 240 that provides steam to the tubes 18a-h forgeneration of hydrogen with either of the platinum type catalyst systems20 shown in FIGS. 19 and 20.

Referring to FIG. 18, the system includes the previously describedhydrogen generating reactor 12, steam generator 14, downstream conduits100a-h and quencher 152. The steam is conveyed from the generator 14 bythe conduit 42 to the top of the single upstream manifold 240 whichincludes a circular conduit 242 and eight inwardly extending conduits244a-h threadably and removably connected to the reactor tubes 18a-h, ashas been described and illustrated for the dual manifolds 96-98 (seeFIG. 11). From the bottom of the circular conduit 242, a conduit 246 andvalve 248 are provided for drainage or for conveying gases or liquidsfrom a source (not shown) to the reactor 12.

As shown in FIG. 19 the steam from the conduits 244a-h flows into theupstream portion of the tubes 18a-h and about the platinum type catalystsystems 20. At the elevated temperatures and pressures previouslydescribed, and in the presence of the platinum type catalyst systems 20,the steam disassociates into hydrogen and oxygen gases with the hydrogendiffusing through the catalyst into the conduit 62. Simultaneously,oxygen and residual steam flows into the downstream portion of the tubes18a-h where they are removed via a manifold 250 having conduitsconnected into the downstream radial bores 28a-h in a fluid tightrelationship. A valve 254 in the manifold 250 is provided to controlflow and pressure in the manifold 250 and tubes 18a-h. By controllingthe opening in the manifold 250 the pressure of the fluids in the tubes18a-h can be increased or decreased for optimizing disassociation anddiffusion of hydrogen through the platinum type catalyst systems 20.

Concurrent with removing oxygen and residual steam from the tubes 18a-h,the hydrogen gas is conveyed from the reactor 12, through conduits100a-h and into quencher chamber 94. The cooled hydrogen gas is fed intoconduit 154 and, if desired, into and through the separator 162.

In the embodiment of the invention schematically shown in FIG. 20, thesteam from conduit 42 is fed into the conduits 62 of the catalyst system20, wherein the hydrogen diffuses outwardly into the tubes 18a-h whilethe disassociated oxygen and residual steam flows through closed endedconduits 62 into the downstream manifold 250 through interconnectingradial passageways 28a-h. In this instance, the diffused hydrogen flowsabout the catalyst systems 20 downstream and into the conduits 100a-hfor quenching and separation, if desired, ready for use upon demand.

In the following embodiments of the invention, we describe illustrativeoverall systems which incorporate the hydrogen generating systems. Theseoverall systems include boilers, gas turbines, internal combustionengines, wankel engines, stirling engines and hydrogen cells.

THE ENERGY SYSTEM IN A BOILER

Referring first to FIG. 21, there is shown a boiler 300 within which theenergy system 10 of the invention is positioned.

The boiler 300 includes an upright cylindrical tank 302 on supportinglegs 304. Water is supplied to the bottom of the tank 302 by an inletconduit 306, and steam for heating and working purposes is conveyed fromthe tank 302 from the outlet conduit 308 extending from the top thereof.

Centrally positioned within the tank 302 is the reactor 12, in anupright position, with vertical tubes 18a-h and catalyst systems 20about a vertical heat generating chamber 16. Extending into the chamber16 is the burner 44 providing an air-fuel mixture to the lower portionthereof. As shown, the catalyst systems 20 are in the lower portions ofthe tubes 18a-h and the burning air-fuel mixture from the burner 44impinges on said portion. To minimize heat loss a baffle 310 iscentrally positioned within the chamber 16 above the burning air-fuelmixture. In the illustrative embodiment the baffle 310 is a spiral woundcoil with its outer periphery secured to the outer wall 312 of thechamber 16. Any residual heat that does escape is exhausted from thechamber 16 through the exhaust pipe 45.

Compressed air for the burner nozzle 44 is provided in this embodimentby a motor driven centrifugal blower 314 having a duct 316 extendingfrom the blower outlet 318 into the chamber 16. Fuel for the burnernozzle 44 is supplied by the generated hydrogen as hereafter describedand by fuel lines 319 having a supply and return conduits 320 and 322connected to a fuel pump 324, and a conduit 326 connected to a commonfuel-hydrogen conduit 328. The common conduit 328 extends through theduct 316 to the burner 44 centrally positioned at the outlet of the duct316 in the lower portion of the chamber 16.

Steam for the reactor 12 is conveyed through a conduit 330 connected tothe top of the tank and to the upstream side of the tubes 18a-h via amanifold 331 which, in this embodiment, is in the lower portion of thereactor 12. Hydrogen generated by the reactor 12 is conveyed from thetop and downstream end of the reactor tubes 18a-h to and through amanifold and a conduit 33 which, in turn, is connected to the commonconduit 328.

Control means, check valves 334 and 336, are connected into the fuel andhydrogen conduit 326 and 333 to control the flow of fuels to the burner44.

During start up, the hydrogen check valve 336 is closed and the fuelcheck valve 334 is open. The fuel at the burner 44 is ignited, and withthe compressed air supplied by the blower 314 throughout the operation,burns to provide heat for the generation of steam in the tank 302.

When the temperature of the water in the tank 302 has been raised andsteam is being generated, it is simultaneously conveyed from the tank302 by conduit 308 for heating and working purposes, and by conduit 330for generating hydrogen. The steam in conduit 330 is fed into the lower(upstream) portion of selected reactor tubes 18, as previouslydescribed, wherein the steam at the super heated temperatures reactswith the catalyst 20 to produce hydrogen.

The generated hydrogen is then conveyed through the upper (downstream)end of the reactor 12. At this juncture the hydrogen check valve 336 isopened and the fuel check valve 334 can be partially or entirely closedso that hydrogen, with or without fuel, is conveyed to the burner 44 viathe common conduit 328.

When on stream, therefore, the generated hydrogen is the fuel source forthe heat that produces steam in the tank 302 and hydrogen in the reactor12.

THE ENERGY SYSTEM IN A GAS TURBINE

In FIG. 22, there is shown the energy system 10 of the inventionproducing hydrogen fuel for operating a gas turbine 400.

The gas turbine 400 includes an air compressor 402, a combustion chamber404, and a turbine wheel 406 within the chamber 404, wherein thecompressed air and fuel form a combustible mixture which drives theturbine wheel 406.

The compressor 402 and turbine 406 are mounted on a common shaft 408which extends from the gas turbine 400 and which, when rotated by theturbine wheel 406, generates mechanical power useful in generatingelectricity.

Extending downstream from and connected to the combustion chamber 404 isthe reactor 12 with its central heating chamber 16 for receiving the hotexhaust gases of combustion before they are exhausted downstream throughexhaust pipe 45. About the reactor 12 is the boiler 14 with its conduit38 for supplying water and with its conduit 42 for supplying steam tothe reactor 12 through an upstream manifold 240.

Prior to the generation of hydrogen within the reactor 12, fuel issupplied to the combustion chamber 404 from a fuel line 412 having fuelsupply and return conduits 414 and 416 connected to a fuel pump 418.Downstream of the pump 418 the fuel line 412 is connected to ahydrogen-fuel mixer 420 from which a conduit 422 extends to the burner44 in the chamber 404.

Initially a conventional starter motor 424 rotates the shaft 408 so thatair is sucked in and compressed by the rotating compressor 402 andconveyed into the combustion chamber 404. At the same time fuel issupplied by the line 412 to the burner 44 and ignited. The compressedair and ignited fuel mixture burns and rotates the turbine wheel 406 todrive the shaft 408, independent of the starter motor 424, for providingthe desired mechanical power.

Once the turbine 400 is on stream, the gases of combustion reachtemperatures within the reactor 12 to generate steam in the boiler 14and hydrogen fuel from steam in the reactor tubes 18a-h, as previouslydescribed. Within the tubes 18a-h the steam is elevated todisassociation temperatures in the presence of a previously describedcatalyst system to produce hydrogen fuel which is conveyed from adownstream manifold 410 and conduit 154 to the hydrogen-fuel mixer 420.With the supply of hydrogen from the reactor 12, the amount of fuelneeded from the fuel line 412 is reduced or cut off by the mixer 420 andis conveyed back to the return fuel conduit 416. Accordingly, thegenerated hydrogen, with or without fuel from line 412, is delivered tothe burner 44 from the mixer 420 by conduit 422 to provide thecombustible mixture for the combustion chamber 404.

THE ENERGY SYSTEM FOR A FOUR CYCLE INTERNAL COMBUSTION ENGINE

In FIG. 23, there is shown the energy system 10 being used to producehydrogen fuel for the four cycle piston driven internal combustionengine 500 for land and marine vehicles, such as automobiles, trucks,farm equipment and boats.

The engine 500 is of the conventional type and includes an engine block502 having cylinders and pistons, not shown, and a fan 504 for an aircooled radiator 506 having conduits 508 and 510 for conveying water toand from the engine block 502, and a conduit 512 for providing water tothe radiator 506 as needed. As in conventional internal combustionengines, there also is a carburetor 514 within which the air-fuelmixture is formed for driving the pistons, and a manifold 516 forexhausting the hot gases of combustion.

Initially fossil fuel, e.g., gasoline, is provided to start and drivethe engine 500 until it is at normal operating temperatures which raisesthe water to temperatures of about 180° F. to 200° F. The fuel issupplied to the carburetor 514 by a fuel line 518 and a fuel pump 520.

Once operating temperatures have been reached, hydrogen is generated bythe system 10 and is used as a fuel for driving the engine 500. For thispurpose the system 10 includes the reactor 12 through which the exhaustmanifold 516 extends to provide heat for the production of hydrogen, andfrom which conduit 522 extends to provide generated hydrogen to thecarburetor 514.

To provide steam for generating hydrogen, an interconnecting conduit 524extends from the hot water conduit 508 to a flasher 526 connected to themanifold 516. In operation, the heat from the exhaust manifold 516generates steam in the flasher 526, and the steam is conveyed from theflasher 526 to the reactor 12 by conduit 528.

Within the reactor 12 hydrogen is generated from the steam provided byconduit 528. The generated hydrogen is then conveyed to the carburetor514 via conduit 522. To insure that only hydrogen reaches the carburetor514 there is provided a separator 162 in the conduit 522 which, aspreviously described, allows only hydrogen to pass therethrough.

When hydrogen is being delivered to the carburetor 514, a valve 536 inthe fuel line 518 can cut off or decrease the supply of fossil fuel, asdesired.

Thus, in this embodiment, fossil fuels initially drive the engine untilthe engine reaches operating temperatures when hydrogen from the reactor12 can be used to drive the engine 500.

THE ENERGY SYSTEM FOR A ROTARY INTERNAL COMBUSTION ENGINE

In FIG. 24 there is shown an energy sytem 10 of the invention whichproduces hydrogen fuel for driving a Felix Wankel rotary internalcombustion engine for vehicles, boats, etc.

The engine 600 is of a conventional type, and includes a block 602 forthe rotor and combustion chamber, not shown, a fan 604 for an air cooledradiator 606 having conduits 608 and 610 for conveying water to and fromthe block 602, a water pump 612 in the conduit 608 for circulating thewater, a carburetor 614 within which the air-fuel mixture is formed fordriving the rotor, a fuel line 616 with a fuel pump 618 therein forproviding fossil fuel to the carburetor 614, and a manifold 620 forexhausting the hot gases of combustion.

About the manifold 620 is the hydrogen generating system 10 whichincludes the reactor 12, the steam generator 14, the conduit 38 andvalve 40 for providing water to the steam generator 14, the conduit 42for conveying steam from the generator to the reactor 12, the waterquencher 152 for cooling the hydrogen generated within the reactor 12and conveyed thereto by the conduits 100a-h, and the conduit 154 forconveying the cooled hydrogen to the carburetor 614 for driving therotor of the engine 600.

In this embodiment the water for the system 10 is delivered from areservoir 622 by pump 623 connected to the conduit 38.

In operation, fossil fuel initially is provided to the carburetor 612via the fuel line 616 and fuel pump 618 for driving the rotor of theengine 600. When the engine reaches operating temperatures the valve 40is opened, and the exhaust gases flowing through the manifold 620 andthrough the system 10 are sufficient to generate steam within generator14 from the water supplied therein and to generate hydrogen within thereactor 12 in the presence of previously described catalyst system. Fromthe reactor 12 the generated hydrogen is conveyed via conduits 100a-hinto the water quencher 152 where the hydrogen is collected and cooledand delivered to the conduit 154. At this time the generated hydrogencan be used to drive the rotary engine 600 with or without fossil fuel.To effect the transition, the control valves 624 and 626 in lines 154and 616, respectively, are regulated to provide the desired quantitiesof hydrogen and fossil fuels.

Here again, fossil fuels initially are used to drive the engine 600until hydrogen is generated within the reactor 12.

THE ENERGY SYSTEM FOR A STIRLING ENGINE

In general, Stirling engines utilize a working gas, such as hydrogen orhelium, in a closed system to drive pistons connected to the drive shaftof the engine. The working gas moves continuously back and forth betweenthe hot space above the piston in one cylinder and the cold spacebeneath the piston in the next cylinder. Between these two spaces thegas passes through a heater which heats the gas, a regenerator whichstores and gives off heat from the gas, and a cooler which cools thegas.

As shown in FIG. 25, the Stirling engine 700 includes heaters 702 whichare positioned in the upper chamber 704 and which are connected betweenthe regenerator 706 and upper side of the cylinders 708. Below theregenerators 706 are coolers 710 which are connected to the oppositeside of the cylinders 708 via passageways 712 (only partially shown).

The heat for the heater 702 is provided by the combustion of an air-fuelmixture in the upper portion of the chamber 704. Fuel is supplied by afuel injector 714 connected to a fuel line 716, and air is suppliedthrough a turbulator 718 which provides flow patterns suitable forcombustion. The hot exhaust gases from the combustion of the air-fuelmixture pass about the heater 702 so that heat is transferred to theinterior working gas. This illustrative Stirling engine is described ingreater detail in a brochure published by United Stirling (Sweden)AB&CO.

The system 10 for the engine 700 is positioned within the upper chamber704 of the engine 700, and includes the steam generator 14 in the formof a coil and the reactor 12 positioned within the generator 14. Wateris supplied to the steam generating coil 14 from a water reservoir 720by a pump 722 through the conduit 38 connected therebetween.

As schematically shown in FIG. 26, the reactor 12 is in the uprightposition and includes vertical reactor tubes 18a-h. This embodimentthere are seven transverse bores at opposite ends of the tubes 18a-h(transverse bores 22a-g and 24a-g) for interconnecting the tubes 18a-h.As illustrated upper transverse bores 22a, c, e and g and lowertransverse bores 24b, d and f are closed while the other transversebores (upper transverse bores 22b, d and f and lower transverse bores24a, c, e and g) are opened. With this configuration, steam providedthrough interconnecting conduit 42 and radial bore 26a flows through thereactor tubes 18a-h, and in the presence of the catalyst systems 20, ina serpentine path. The generated hydrogen and other fluids from thereactor 12 are conveyed therefrom through radial bore 26h and conduit154 to the separator 162, which, as previously described, separates thegenerated hydrogen from the other fluids. As now will be explained, thishydrogen can be used as the fuel for combustion in the chamber 704.

Initially the valve 726 in the fuel line 716 is opened and the valve 728in the conduit 154 is closed. Accordingly, fuel, such as fossil fuel orother stored fuel, is provided from a source, not shown, to the fuelinjector 714. The heat from the products of combustion within the upperchamber 704 concurrently heats the working gas in the heaters 702 aswell as the water in the steam generator 14 and the steam in the reactor12 by passing therearound and therethrough the generator 14 and reactor12. The hydrogen and other fluids generated in the reactor 12 flowthrough the conduit 154 to the separator 162 where only hydrogen isallowed to flow downstream. When the hydrogen fuel has reachedappropriate levels, the valve 728 in the conduit 154 is opened and thevalve 726 in the fuel line 716 can be closed or throttled. In the eventthat the valve 726 is closed, then only generated hydrogen will besupplied to the fuel injector 714 as the fuel for the combustiblemixture. In the event that the valve 726 in the fuel line 716 is onlythrottled, then the hydrogen and the other fuel will be mixed andsupplied to the fuel injector 714 as the fuel for the combustiblemixture.

Consequently, in this embodiment the heat for the working gas for theengine 700 is used to generate hydrogen which can be used as fuel forthe combustible mixture once the engine is at operating temperatures.

HYDROGEN GENERATING SYSTEM FOR FUEL CELLS

In a fuel cell electricity is generated by a chemical reaction in whichthe reactants are continuously fed to the cell as the reaction proceeds.One reactant is a fuel, such as hydrogen, and the other reactant is anoxidant, such as air or oxygen. So long as the reactants, hydrogen andoxidant, are fed into the cell and the reaction product, water, isremoved from the cell, the fuel cell generates power in the form ofdirect current electricity.

In FIG. 27 there is illustrated the hydrogen generating system 10 whichproduces hydrogen for a Francis Bacon hydrogen-oxygen type fuel cell800.

The fuel cell 800 includes a housing 802 and a pair of spaced electrodes804 and 806, such as porous nickel electrodes. The electrodes 804 and806 divide the housing 802, into three chambers, 808, 810 and 812. Theintermediate chamber 810 contains an electrolyte 814, such as potassiumhydroxide, which is conveyed to and from the chamber 810 and a reservoir816 through conduit 818.

For the electrical generating chemical reaction, air or oxygen is fed toand unreacted air or oxygen is fed from the outer chamber 812 through aconduit 820. Simultaneously hydrogen gas is fed to the outer andopposite chamber 808 through an upper inlet conduit 822, and theunreacted hydrogen gas is conveyed from the chamber 808 by a lowerconduit 824. To remove any condensate a collector 825 is provided in theconduit 824. The direct current electricity generated within the cell800 is conducted between the electrodes 806 and 804 and the illustrativecircuit 826.

In this fuel cell system, the hydrogen gas is provided by hydrogengenerating system 10 which includes the reactor 12 and the steamgenerator 14.

Water for the steam generator 14 is provided from a reservoir 828. Makeup line 830 is connected to a source of water not shown. Pump returnline is 832. Water for the generator 14 is conveyed from the reservoir828 by a pump 836 through the conduit 38 and control valve 40 into thegenerator chamber 32.

Heat from burner 44 (or heat from another source) raises the temperaturein the reactor 12 to about 1000° F. to 2000° F., whereupon steam isgenerated in the generator 14 and conveyed to the reactor 12 through theconduit 42, radial bore 28h and into tube 18h. The configuration of thebores within the reactor 12 is similar to that shown in FIG. 17 so thatthe steam passes about the catalysts 20 in the reactor tubes 18h-a in aserpentine path as previously described.

Within the tubes 18a-h the steam disassociates into hydrogen and oxygen,and hydrogen passes through the catalysts 20 into the conduits 62,interconnecting conduits 100a-h and into the quencher 152. Pump 837provides cooling water from the reservoir 834 through the conduit 210 toa cooling chamber 176, and water is returned to the reservoir 834through conduit 212.

At the same time disassociated oxygen, and any residual steam, isconveyed from tube 18a through bore 226 and conduit 238 to the reservoir828. As shown the disassociated oxygen can be removed from the reservoirby conduit 838 which includes control valve 840 for such purposes.

From the quencher 152 the cooled hydrogen gas is conveyed to theseparator 162 by the conduit 154 where only hydrogen is allowed todiffuse through the membrane 216 and into conduit 218. Any residualoxygen and water passes about the membrane 216 into the conduit 220which is connected at its other end into the reservoir 828.

Downstream, the conduit 218 is connected to conduit 842. In the conduit842 there is a pump 846 for conveying the hydrogen to both conduits 822and 844. One way valves 845 in conduits 218, 824, 844 and 822 insure theflow of hydrogen in the direction indicated by the arrows.

The hydrogen conveyed to conduit 822 enters the fuel cell chamber 808 togenerate electricity while the hydrogen in the conduit 844 is used withthe pump 846 to increase the yield of hydrogen in the reactor 12 as willpresently be described.

From the conduit 844 the hydrogen is fed into a manifold 848 connectedto the conduits 62 of the catalyst systems 20 in a fluid tightrelationship as schematically shown in FIG. 27. The pump 846 influencesthe quantities of hydrogen gas diffused through the catalysts 20 in thereactor tubes 18a-h by creating a negative pressure in the conduits 62relative to the positive steam pressure flowing about the catalyst 20 inthese same tubes 18a-h. In effect, the pump 846 continually sweeps thediffused generated gases out of the reactor 12. In doing so, theequilibrium on the steam side of the catalysts 20, within the tubes18a-h, becomes upset and causes further disassociation of the steam intohydrogen and oxygen in trying to maintain-equilibrium.

In this embodiment, therefore, the generated hydrogen is usedsimultaneously to generate electricity in a fuel cell and to increasethe yield of the generated hydrogen itself.

In addition to using hydrogen as a fuel, as shown in the illustrativeembodiments of FIGS. 21-27, the hydrogen generated by the system 10 ofthe invention can be used as a chemical in forming products and inchemical processes. For example, the generated hydrogen can be used inthe manufacture of ammonia, nitrates, amines and alcohols (e.g.,methanol), as well as in the hydrogenation of organic compounds. Thegenerated hydrogen also can be used in steel making and other metalindustries, the gasification and liquification of coal, the recovery ofshale oil, the production of protein foods, and in total watermanagement programs.

Thus, the invention in its broader aspects is not limited to thespecific described embodiments and departures may be made therefromwithin the scope of the accompanying claims without departing from theprincipals of the invention and without sacrificing its chiefadvantages.

What is claimed:
 1. In an energy system, the method of producinghydrogen comprising:placing porous material in a reaction zone of areactor; heating said reaction zone; heating water; feeding the water atelevated temperatures through said reaction zone for interaction withthe porous material resulting in the disassociation of hydrogen from thewater; and diffusing the resulting hydrogen through said porous materialto separate the hydrogen from the water and diassociated oxygen.
 2. Themethod according to claim 1 further comprising the step of combustingsaid hydrogen to aid in said heating.
 3. The method according to claim 1further comprising the steps of:conveying the hydrogen to an engine asthe fuel for combustion therein; combusting the hydrogen in said engine;and applying heat from said combustion to said water to increase saidheating of said water, the temperature thereof being sufficientlyelevated to convert the water to steam.
 4. The method according to claim3 wherein the engine is selected from the group consisting of the pistondriven internal combustion engine, the rotary driven internal combustionengine, the gas turbine and the stirling engine.
 5. The method accordingto claim 1 further comprising:reacting the generated hydrogen in a fuelcell for the generation of electricity.
 6. In an energy system, themethod of producing hydrogen comprising the steps of:placing porousmaterial in reaction zones in a reactor; heating said reaction zones;heating water for the generation of steam; feeding said steam to thereaction zones for interaction with said porous material resulting inthe disassociation of hydrogen from said steam; diffusing the resultinghydrogen through said porous material to separate the hydrogen from thesteam and disassociated oxygen; subsequently passing a portion of saidhydrogen through said reaction zones to regenerate said porous material;and alternating the flow of said steam and said portion of said hydrogenvia transversed and radial passages in the reactor adapted tointerconnect the longitudinal reaction zones to each other, therebypermitting the interleaving of said steps of feeding and passing.
 7. Themethod of producing hydrogen according to claim 6 wherein saidalternating is responsive to a sensing of the concentration of saidhydrogen.
 8. The method of generating hydrogen according to claim 6wherein said porous material in each zone is metallic and containsinnumerable sites on its surface, which, with the elevated temperaturesin each zone, effect the generation of hydrogen.
 9. The method ofgenerating hydrogen according to claim 8, wherein said porous materialis formed of a cellular structure of interconnected metal filaments. 10.The method of generating hydrogen according to claim 9 wherein saidporous material is selected from the group consisting of iron, copper,silver, nickel, palladium, platinum and iron-nickel and molybdenum. 11.The method of generating hydrogen according to claim 6 wherein the steamin said zones and in the presence of said porous material is elevated toa temperature from 1000° F. to about 2000° F. for the generation ofhydrogen.
 12. The method of producing hydrogen according to claim 6further comprising the step of quenching the hydrogen, oxygen andresidual steam to reduce the temperatures thereof.
 13. The method ofproducing hydrogen according to claim 6 wherein said zone heating stepresults in a heating of the zones to a temperature of about 1000° F. toabout 2000° F., said method further comprising the step of quenching thehydrogen to reduce the temperature thereof.
 14. The method of producinghydrogen comprising the steps of:placing porous material in the reactionzones of a reactor; heating said reaction zones and said porousmaterial; heating water to generate steam therefrom; feeding said steaminto a first set of selected ones of said reaction zones to permitinteracting of said steam at elevated temperatures with said porousmaterial to produce hydrogen until said porous material becomesdeactivated by oxidation; feeding a reducing agent into a second set ofother ones of said reaction zones wherein said porous material hasbecome deactivated to reactivate said porous material; transferring heatbetween said first and second sets of reaction zones to thereby increasethe production of hydrogen; and alternating the flow of said steam andsaid reducing agent between sets of reaction zones.
 15. The method ofproducing hydrogen according to claim 14 further comprising the step ofdiffusing the hydrogen through said porous material to separate thehydrogen from the steam.
 16. The method of producing hydrogen ready foruse, upon demand, according to claim 15, comprising:detecting whetherthe hydrogen producing zones are producing hydrogen, and controlling theflows of steam and reducing agent so that when the porous material inthe hydrogen producing reaction zones becomes deactivated, reducingagent is fed thereto to reactivate the porous material, and when theporous material in the deactivated reaction zones becomes reactivated,steam is fed thereto.
 17. The method of producing hydrogen according toclaim 16 wherein said reducing agent is a portion of the hydrogenproduced by said interacting.
 18. The method of producing hydrogen fromsteam according to claim 17, wherein said porous material comprises aweb like structure of interconnected filaments of metal.
 19. The methodof producing hydrogen from steam according to claim 18 wherein thetemperature of the steam in the reaction zones and in the presence ofthe porous material is elevated to the range of approximately 1000° F.to approximately 2000° F.
 20. The method of producing hydrogen asrecited in claim 14 further comprising the steps of:conveying the fluidsof reaction from the hydrogen producing zones to a separator, andseparating hydrogen from said fluids.